Device for performing consolidation and method of use thereof

ABSTRACT

A preforming device and method of use thereof, the device including a rack, a pinion, belt, belt tensioning feature, and mechanism for supporting a variably appliable enhanced pressure, such as may be applied using a bladder or bladders having one or more valves, the device capable of engaging a mandrel to form at least one ply and a binder against the exterior of the mandrel.

This application is based upon and claims the benefit of priority fromthe prior U.S. Provisional Application No. 60/814,075 filed on Jun. 16,2006, the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a device that simultaneously shapes andconsolidates multiple plies of composite fabrics or other material to beformed or preformed, while maintaining fiber orientation andregistration of the ply surface.

2. Background of the Related Art

There is a general need in the art of preforming to have multiple pliesor other similar materials accurately indexed with no ply distortion ina complex geometry.

In the prior art, individuals would lay-up each ply on a mold,attempting to eliminate distortion by hand, while working out wrinklesas best as possible. Quality depends on the operator and is limited, forexample, by finger pressure applied. Among other things, problems existwith operator variation and capabilities to eliminate distortion, aswell as the cost in time spent manually laying up individual plies,while maintaining proper orientation.

SUMMARY OF THE INVENTION

The present invention overcomes the above identified problems, as wellas others, by providing a device and method for providing uniformconsolidation and orientation of a complete ply pack or other materialto be formed or preformed.

Among other advantages, the present invention allows the forming orpreforming to be accomplished in much less time than prior art systems.In addition, the ply orientation, consolidation, and non-distortion areconsistently repeatable with the present invention.

The preforming device of one exemplary embodiment of the presentinvention includes a rack, a pinion, belt, belt tensioning feature, andmechanism for supporting a variably appliable enhanced pressure, such asmay be applied using a bladder or bladders having one or more valves. Inthis exemplary embodiment, the rack portion has edges for engaging theedges of the mandrel section. As the pinion is activated, it places theleading edge of the mandrel engages the belt and the material to beformed placed on the belt. The rack continues application of a force ofthe mandrel against the belt. Due to the elasticity of the belt, thebelt generally conforms to the shape of the mandrel. This part of theprocess forces the materials against the mandrel, eliminating or greatlyreducing the possibility of distortion, wrinkles and improper indexingof the material being shaped.

Upon the mandrel being driven by the rack and pinion to a predeterminedstop position, the mechanisms for supporting a variably appliableenhanced pressure against the sides of the mandrel are activated (e.g.,via valves). This operation completes the preforming consolidation ofthe material, accurately and with concise positioning.

In one exemplary embodiment, the rack and pinion portions have generallylinear shaped teeth and drive the mandrel with a downward force toengage the mandrel with the elastic belt, which is tensioned by a weightso as to accurately apply force against the material to be preformed.

Reversal of the rack and pinion operation then removes the preformedmaterial consolidated onto the mandrel from engagement with the belt.

Another exemplary embodiment includes a device for performingconsolidation, the device comprising a rack; at least two rollers,wherein the at least two rollers include a pair of extensions extendingfrom ends of the rollers, and wherein the extensions are slidable inslots in retainers for the rollers; a belt surrounding the at least tworollers; a weight, wherein the belt serpentines around the at least tworollers and the weight, such that the at least two rollers are biasedtoward each other; a mandrel having an axial direction and engageablewith the rack: a material to be consolidated being applied to thesurface of the belt facing a leading edge of the mandrel; and a mandrelengaging mechanism; wherein the mandrel engaging mechanism is capable ofdriving the mandrel in a direction parallel to the axial direction ofthe mandrel and generally perpendicularly to a surface of the belt froma first position to second position; wherein two parallel wall portionsare located on opposite sides of the mandrel when the mandrel is driveninto the belt to the second position; wherein an inflatable bladder islocated on at least one of the parallel wall portions; and wherein eachinflatable bladder is capable of compressing against a side of themandrel.

Another exemplary embodiment includes an apparatus for uniformlyconsolidating and orienting a material to be formed, the apparatuscomprising a rack, at least two rollers; a belt surrounding the at leasttwo rollers; a tensioning feature; and a mandrel having an axialdirection, the material to be formed applied to a surface of the belt,wherein the rack is capable of engaging the mandrel and driving themandrel in a direction parallel to the axial direction of the mandreland generally perpendicularly to a surface of the belt.

The material may a composite material. The apparatus may further includea pinion that engages the mandrel to drive the mandrel into the belt.The rack and pinion may include teeth that engage the mandrel.

The apparatus may further include a mechanism for applying a variablyenhanced pressure to the mandrel. The mechanism for applying a variablyenhanced pressure may include parallel wall portions located on oppositesides of the mandrel when the mandrel is driven into the belt. Theopposing parallel wall portions may include at least one inflatablebladder.

The tensioning feature of the apparatus may include at least oneselected from a group consisting of a weight, a biasing mechanism, andan electromagnetically controlled roller. The biasing mechanism may be aspring. The tensioning feature may include a cylindrical weight, whereinthe belt wraps around the cylindrical weight.

The rollers may include a pair of extensions extending from ends of theroller, and wherein the extensions are inserted slidably in slots inretainers for the rollers. The apparatus may further include a biasingmechanism for biasing the at least two rollers toward each other.

Another exemplary embodiment of the invention includes method of shapingand consolidating multiple plies of a material, the method comprisinglocating at least one ply of a material with an applied binder on asurface of the belt; engaging a mandrel in a rack of a performingapparatus at a first position, wherein the performing apparatuscomprises at least two rollers; a belt surrounding the at least tworollers; and a tensioning feature; and driving the mandrelperpendicularly to the surface of the belt with the applied material toa second position.

The method may further include providing additional material with the atleast one ply and binder, wherein the additional material includes atleast one selected from a group consisting of a sensor, a heatercomponent, and a buffer layer.

The method may further include tensioning the at least two rollers, suchthat a minimal distance is maintained between the rollers before themandrel is driven into the belt and the material, driving the mandrelperpendicularly into the belt and the material, such that the rollersare driven apart from one another, or applying a generally even pressureto the leading edge of the mandrel.

The method may include maintaining at least one element of the rack at apredetermined, uniform temperature, wherein the predeterminedtemperature is a raised temperature above ambient and, wherein the atleast one element is selected from a group consisting of the belt, theat least one of the rollers, and the mandrel.

The method may include compressing the side portions of the mandrel byengaging an enhanced pressure mechanism when the mandrel is in thesecond position, wherein engaging the enhanced pressure mechanismincludes inflating a bladder on at least one of a pair of parallel wallson opposite sides of the mandrel when the mandrel is in the secondposition.

The method may include maintaining the enhanced pressure for apredetermined period of time, such that the at least one ply and binderset or determining the thickness of the ply and binder based on thetension applied by the tensioning feature and the compression applied bythe enhanced pressure mechanism.

Another exemplary embodiment includes a device for performingconsolidation, the device comprising means for engaging a mandrel,having an axial direction, means for positioning a material to be formedwith a surface perpendicular to the axial direction of the mandrel;pressure means for applying a generally uniform enveloping pressure to asurface of the mandrel with the material to be formed applied; drivingmeans for driving the mandrel into the pressure means and into thesurface of the material; and compression means for applying a variablyenhanced pressure to sides of the mandrel when the mandrel is driveninto the pressure means.

Additional advantages and novel features of the invention will be setforth in part in the description that follows, and in part will becomemore apparent to those skilled in the art upon examination of thefollowing or upon learning by practice of the invention.

BRIEF DESCRIPTION OF THE FIGURES

In the drawings:

FIG. 1 is a perspective view of an exemplary preforming machine having abelt with a rack and pinion, in accordance with one embodiment of thepresent invention;

FIGS. 2A-2D present representative side views of various stages ofoperation of the present invention, in accordance with the exemplaryembodiment of FIG. 1; and

FIG. 3 presents a side view of an embodiment of the present inventionwith layers of material to be formed.

DESCRIPTION OF THE INVENTION

FIG. 1 shows a perspective view of an exemplary preforming machine 1having a housing 2 for producing a composite material containingmultiple fiber plies or other similarly formable materials (alsointerchangeably referred to herein as “the laminate” or “the compositematerial”). A mandrel 4 serves as a first component in a tool string forcreating the composite material. The tool string, as used herein, refersto the tools used in conjunction with the preforming machine 1 to createa part (e.g., a composite part made from the laminate, such as anaircraft part).

A belt 8, such as a fabric belt, contacts two or more rollers held byend retainers 30, 31. Belt 8 also supports weight or other tensioningfeature 25. The material to be formed is positioned on a surface of thebelt 8 (as shown in FIG. 3). In the embodiment shown in FIG. 1, afterapplying a material to be formed onto a surface of the belt 8, themandrel 4 is inserted into slots 5 in a rack 6, which allows the mandrel4 to be driven, for example, via a pinion 7 attached to (e.g.,circumferentially frictionally fitting upon) a shaft.

The rack 6 is positioned such that the mandrel 4 engaged thereby is ableto engage the belt 8 upon being driven downward, as shown in FIG. 1.Thus, the mandrel is driven by a mandrel engaging mechanism engageablewith the mandrel. As shown in FIG. 1, the rack 6 includes tworectilinear components engaging outside edges of the mandrel 4. Gearswithin the rack 6 are driven via a shaft (e.g., pinion 7) to which ahand crank or other driving device is attachable.

Upon turning of the pinion 7, gear mechanisms (e.g., gears and/or geardriven chain links) in or operating in conjunction with rack 6 (e.g.,within slots 5) engage engagement features (e.g., gear engaging openingsor teeth) located at or near each end of the mandrel 4. Engagement ofrack 6 and mandrel 4 causes travel of mandrel 4 downward, as shown inFIG. 1, such that lower end of mandrel 4, as shown in FIG. 1, is drivengenerally perpendicularly into the belt 8 with emplaced plies andbuffering layer.

In one embodiment, two sets of pinions 7, gear mechanisms, andengagement features are used, the two pinions 7 being located at ends ofa shaft. The ends of the mandrel 4 are thus cooperatively driven intandem within the slots 5, such that the mandrel progresses generallyevenly throughout its length along a leading edge (lower edge, as shownin FIG. 1) against the belt 8

The belt 8, which is of a predetermined length, is tensioned by atensioning feature 25. For example, as shown in FIG. 1, the belt 8serpentines about a weight (e.g., a roller), and two or more rollers 26a, 26 b, 26 c, 16 d. In other embodiments, other features are usable totension the belt. These features may include biasing mechanisms such asspring or resistance features secured to the belt, or other tensioningfeatures, such as electro-magnetically controlled rollers.

In one embodiment, one or more of the rollers 26 a, 26 b, 26 c, 26 dhave extensions (e.g., pins) extending from both ends, allowing therollers to slide via the extensions within slots 28. In someembodiments, the rollers are grouped in pairs 26 a, 26 b and 26 c, 26 d,the pairs being coupled via the extensions of the rollers 26 a, 26 b, 26c, 26 d engaging end retainers 30, 31, respectively.

The paired rollers 26 a, 26 b and 26 c, 26 d thus able to move slidablyin tandem within the slots 28. The tensioning feature 25 tends tomaintain a tension upon the belt 8, the belt 8, in turn, due to thetension thereon, tending to bias the pairs of rollers 26 a, 26 b and 26c, 26 d toward one another, as shown in FIG. 1, within the slots 28. Thepairs of rollers 26 a, 26 b and 26 c, 26 d may also be biasedadditionally or via other mechanisms and/or methods towards one another,such as by use of springs connecting the end retainers 30, 31, or by useof hydraulic or other mechanisms engaged with the end retainers 30, 31or rollers 26 a, 26 b, 26 c, 26 d.

The preforming machine 1 further comprises a pair of parallel wallportions 35, 36 or other mechanisms for supporting a variably appliableenhanced pressure, such as one or more inflatable bladders (see, e.g.,inflatable bladders 35 a, 36 a best shown in FIGS. 2A-2D). In theexemplary embodiment shown in FIG. 1, wall portions 35, 36 are attached(e.g., via nuts and bolts or welds) to the housing 2 at each end of thewall portions 35, 36. In one exemplary embodiment, opposing inflatablebladders are attached to wall portions 35, 36, the bladders beinginflatable via one or more valves 37.

Operation of the present invention in accordance with FIG. 1 occurs asfollows. One or more plies along with an applied binder (e.g., hardenerand resin material that “cure” so as to harden) are emplaced on asurface of the belt 8 facing the leading edge of the mandrel 4.Additional materials may also be included with the plies and binder,such as sensors, heater components, or other devices or materials to beembodied in the part to be made using the laminate formed. Optionally, abuffering layer (e.g., non-reactive plastic film) is overlayed theemplaced plies and binder. The mandrel 4 is then engaged with rack 6. Ahandle or other driving mechanism coupled to the pinion 7 (e.g., viashaft 20) is used to drive the pinion 7 rotationally so as to engage thegear mechanisms and thus the engagement features of the mandrel 4.

As the mandrel 4 engages the belt 8 by moving down, as shown in FIG. 1,upon being driven by the pinion 7 and engaging gear mechanisms, thepairs of rollers 26 a, 26 b and 26 c, 26 d tend to be driven apart fromone another, as shown in FIG. 1, so as to allow the mandrel 4 to passtherebetween, past the rolling rollers. The tension in the belt 8,however, tends to continue to bias the pairs of rollers 26 a, 26 b and26 c, 26 d toward one another, as shown in FIG. 1. Thus, the belt 8passing about the rollers 26 a, 26 b, 26 c, 26 d tends to wrappablyenvelop the passing mandrel 4 and overlayed plies/binder, such that thesurface of the mandrel 8 engages the surface of the belt 8 andplies/binder and a generally even pressure is thereby applied to theleading edge (i.e., lower edge as shown in FIG. 1) of the mandrel 8 andplies/binder.

One result of the uniform enveloping pressure of the belt 8 applied tothe mandrel 4 and plies/binder is that the a generally uniform thicknessof laminate is formed thereby at the portion of the laminate located atthe leading edge of the mandrel 4 (i.e., bottom edge of mandrel 4, asshown in FIG. 1). Thus, for example, a very uniform fold in theplies/binder about the end of the mandrel 4 may be obtained, and smoothapplication of pressure from the belt 8 to the sides of the mandrel 4and bulk of the plies/binder may be obtained.

Further, in one embodiment, one or more of the rollers 26 a, 26 b, 26 c,26 d, belt 8, mandrel 4, and/or other parts of the preforming machine 1are maintained at a generally uniform temperature (e.g., heated to araised uniform temperature above ambient), so as to enhance“tackification” (e.g., stickiness and softening of the resin/hardenerduring the forming process within the preforming machine 1).

Once the mandrel 4 and plies/binder are enveloped within the belt 8 andhave traveled to a position such that the engaged surfaces are locatedbetween the parallel wall portions 35, 36, at least one of the bladdersor other enhanced pressure devices are engaged, such as by inflating thebladders to a predetermined air or fluid pressure, so as to applygenerally uniform pressure to the plies/binder overlaying the sides ofthe mandrel 4. The pressure of the inflated bladders or other enhancedpressure devices is maintained for a predetermined period so as to setthe plies/binder. For example, for some binder material, the time periodmay be about five minutes. By applying a generally uniform pressure viathe bladders or other enhance pressure devices via the belt 8 along theside surfaces of the mandrel 4 and plies/binder, a uniform compressionto produce a generally uniform thickness of plies/binder may beobtained.

The thickness of the plies/binder thus produced may be varied by varyingthe tension in the tensioning feature 25 (e.g., by varying the mass ofthe weight used), particularly with respect to the thickness at theleading edge of the mandrel 4, and by varying the amount of pressureand/or compression applied via the bladders or other enhanced pressuredevices (for the portions of the plies/binder along the sides of themandrel 4).

After the forming process is completed within the preforming machine 1,the plies/binder are typically removed and allowed to cure (e.g., theresin and hardener to cure), so as to form a generally rigid part.

FIGS. 2A-2D present representative side views of various stages ofoperation of the present invention, in accordance with the exemplaryembodiment of FIG. 1.

In FIG. 2A, the mandrel 4 is shown at a position prior to engagementwith the belt 8 and plies/binder. Tensioning feature 25 places a tensionon the belt 8. End retainers 30 and 31 and respective pairs of attachedrollers 26 a, 26 b and 26 c, 26 d are drawn toward one another to aminimal separation distance another by virtue of tension on the belt 8.An axial direction of the mandrel is shown with a dashed line. The axialdirection of the mandrel is shown as being generally perpendicular tothe upper surface of the belt 8 wrapped over rollers 26 a, 26 b, 26 c,and 26 d. The material to be formed is placed on this upper surface.

As shown in FIG. 2B, downward movement of the mandrel 4 and plies/binderhave resulted in the mandrel 4 beginning to engage the belt 8 andplies/binder. End retainers 30 and 31 and respective pairs of attachedrollers 26 a, 26 b and 26 c, 26 d have separated, as shown in FIG. 2B,due to impact of the mandrel 4 with the belt 8. Tensioning feature 25has displaced upwardly slightly, as shown in FIG. 2B, in response toengagement of the mandrel 4 with the belt 8 and plies/binder.

In FIG. 2C, the mandrel 4 and plies/binder have been moved to a positionbetween the parallel wall portions 35, 36 and the correspondingmechanisms for supporting a variably appliable enhanced pressure 35 a,36 a, such as one or more inflatable bladders. The belt 8 wraps aroundthe leading edge 4 a of the mandrel 4, so as to generally uniformlycompress the portion of the plies/binder wrapped about mandrel 4 at theleading edge 4 a. End retainers 30 and 31 and respective pairs ofattached rollers 26 a, 26 b and 26 c, 26 d moved to a slightly lesserseparation distance due to positioning of the mandrel 4 andplies/binder. Tensioning feature 25 has displaced upwardly to theposition shown in FIG. 2B, in response to positioning of the mandrel 4and engagement thereof with the belt 8 and plies/binder.

In FIG. 2D, the mandrel 4 and plies/binder remain in the position shownin FIG. 2C. The mechanisms for supporting a variably appliable enhancedpressure 35 a, 36 a, such as one or more inflatable bladders, have nowbeen engaged (e.g., bladders inflated), so as to generally uniformlycompress the portion of the plies/binder along the side edges of themandrel 4. Thus, a generally uniform pressure is applied to theplies/binder at both the leading edge 4 a and along the sides of themandrel 4.

FIG. 3 shows an embodiment of a plurality of layers of material to beformed located on the surface of the belt facing the leading edge of themandrel such that the layers have a surface generally perpendicular tothe axial direction of the mandrel. However, the material to be formedmay be only one layer of material with a binder. The material to beformed may include any number of layers of material with a binder. Thismaterial may be a composite material or a laminate.

Although exemplary embodiments of the present invention have now beendiscussed in accordance with the above advantages, it will beappreciated by one of ordinary skill in the art that these examples aremerely illustrative of the invention and that numerous variations and/ormodifications may be made without departing from the spirit or scopeinvention.

1. A device for performing consolidation, the device comprising: a rack;at least two rollers, wherein the at least two rollers include a pair ofextensions extending from ends of the rollers, and wherein theextensions are slidable in slots in retainers for the rollers; a beltsurrounding the at least two rollers; a weight, wherein the beltserpentines around the at least two rollers and the weight, such thatthe at least two rollers are biased toward each other; an elongatedmandrel having an elongation direction and engageable with the rack: amaterial to be consolidated being applied to a surface of the beltfacing the leading edge of the mandrel; and a mandrel engagingmechanism; wherein the mandrel engaging mechanism is capable of drivingthe mandrel in a direction parallel to the elongation direction of themandrel and generally perpendicularly to the surface of the belt withthe applied material from a first position to second position; whereintwo parallel wall portions are located on opposite sides of the mandrelwhen the mandrel is driven into the belt to the second position; whereinan inflatable bladder is located on at least one of the parallel wallportions; and wherein each inflatable bladder is capable of compressingagainst a side of the mandrel.
 2. An apparatus for uniformlyconsolidating and orienting a material to be formed into a laminate, theapparatus comprising: at least two rollers spaced apart from oneanother; a belt extending across and supported by the at least tworollers; a tensioning feature placing a tension on the belt; a mandrelhaving an elongation direction, in which the mandrel is movable in adirection parallel to the elongation direction between a non-engagedposition and an engaged position in which the mandrel engages the beltand the material disposed thereon and passes, at least in part, betweenthe at least two rollers and the belt and the material moves with themandrel between the non-engaged position and the engaged position; andat least one inflatable bladder so disposed as to apply a consolidationpressure to the belt to consolidate the material to be formed betweenthe belt and the mandrel when the mandrel is in the engaged position. 3.The apparatus of claim 2, wherein the material is a composite materialthat forms the laminate.
 4. The apparatus of claim 2, furthercomprising: a rack supporting and controlling movement of the mandrelbetween the non-engaged position and the engaged position; and a pinionthat engages the mandrel to drive the mandrel into the belt.
 5. Theapparatus of claim 4, wherein the rack and pinion comprise teeth thatengage the mandrel.
 6. The apparatus of claim 2, further comprising: amechanism for applying a variably enhanced pressure to the mandrel. 7.The apparatus of claim 6, wherein the mechanism for applying a variablyenhanced pressure includes parallel wall portions located on oppositesides of the mandrel when the mandrel is driven into the belt and thevariably enhanced pressure is applied in a direction perpendicular tothe direction of movement of the mandrel.
 8. The apparatus of claim 7,wherein the opposing parallel wall portions include the at least oneinflatable bladder.
 9. The apparatus of claim 2, wherein the tensioningfeature includes at least one selected from a group consisting of aweight, a biasing mechanism, and an electromagnetically controlledroller.
 10. The apparatus of claim 9, wherein the biasing mechanism is aspring.
 11. The apparatus of claim 9, wherein the tensioning featureincludes a cylindrical weight, and wherein the belt wraps around thecylindrical weight and the belt is an endless belt.
 12. The apparatus ofclaim 2, wherein at least one of the rollers includes a pair ofextensions extending from ends of the roller, and wherein the extensionsare inserted slidably in slots in retainers for the rollers.
 13. Theapparatus of claim 12, further comprising: a biasing mechanism forbiasing the at least two rollers toward each other.
 14. The device ofclaim 1, wherein the elongated mandrel comprises a leading edge.
 15. Theapparatus of claim 2, wherein the elongated mandrel comprises a leadingedge and the mandrel defines a non-cylindrical forming surface.
 16. Adevice for forming an aircraft component from a composite material, thedevice comprising: a rack; at least two rollers, wherein the at leasttwo rollers include a pair of extensions extending from ends of therollers, and wherein the extensions are slidable in slots in retainersfor the rollers; a belt surrounding the at least two rollers; a weight,wherein the belt serpentines around the at least two rollers and theweight, such that the at least two rollers are biased toward each other;an elongated mandrel having an elongation direction and engageable withthe rack: a material of an aircraft component to be consolidated beingapplied to a surface of the belt facing the leading edge of the mandrel;and a mandrel engaging mechanism; wherein the mandrel engaging mechanismis capable of driving the mandrel in a direction parallel to theelongation direction of the mandrel and generally perpendicularly to thesurface of the belt with the applied material from a first position tosecond position; wherein two parallel wall portions are located onopposite sides of the mandrel when the mandrel is driven into the beltto the second position; wherein an inflatable bladder is located on atleast one of the parallel wall portions; and wherein each inflatablebladder is capable of compressing against a side of the mandrel.
 17. Thedevice of claim 16, wherein the composite material comprises two sheetsof material bound by a binder.